Forming method and product



1, 1967 R. s. INLOW 3,333,451

FORMING METHOD AND PRODUCT Filed May 11, 1965 INVENTOR. Haber? S. I7/0W 7 ATTORNEY United States Patent Ofi ice 3,333,451 Patented Aug. 1, 1967 3,333,451 FORMING METHOD AND PRODUCT Robert S. Inlow, Los Angeles, Calif., assignor to Aluminum Company of America, Pittsburgh, Pa., a corporation of Pennsylvania Filed May 11, 1965, Ser. No. 454,779 4 Claims. (Cl. 72-179) This invention relates to a method of forming sheetlike materials into free form or predetermined three dimensional patterns and the product produced thereby.

It is known to form sheet-like materials into various shapes by deep drawing or stamping operations. Such systems are, however, inherently inflexible and involve the expense of providing a different die set for every modification to the desired configuration, as well as requiring high press capacities.

It is an object of this invention to provide a simple method of economically bending sheet-like materials into simple or complex forms, without the need for substantial modification to equipment to produce different patterns.

It is another object of this invention to provide a method of bending sheet-like materials along a simple or complex curved path without thinning of the material.

It is another object of this invention to provide a method of producing complexly curved sheet-like members having the path of curvature and the angle of bend conformed to a predetermined pattern.

These and other objects and advantages of the invention will be understood from the following description of the invention, on reference to the illustrations appended hereto in which:

FIG. 1 is a fragmentary perspective view of a sheet- 'like material being formed in accordance with the method of the invention;

FIG. 2 is an enlarged fragmentary view showing a sheet-like material being passed through a pair of roller dies;

FIG. 3 illustrates several types of roller dies which may be employed in the method of this invention;

FIG. 4 is a perspective view of a simple curve formed by the method of this invention;

FIG. 5 is a perspective view of a complex form created by the method of this invention;

FIG. 6 is similar to FIG. 5 but illustrates a different complex form.

Referring now to the drawings in greater detail, FIGS. 1 and 2 show a deformable sheet 1 being formed according to the method of this invention. A pair of roller dies bend the sheet as it is moved longitudinally through the dies. The female die 2 has a substantially V-shaped annular channel 4, while the male die 3 has a complementary configuration. In employing the method, the sheet 1 may be moved through the dies 2, 3 by having one or more of the dies positively driven or by independent driving means. The complementary dies cause the panel to bend without thinning the material. The panel may be moved laterally as it proceeds longitudinally through the dies, thereby creating a bend line which is curved or irregular, This permits the creation of complex three dimensional curved shapes without the need for deforming the sheet under substantial pressure.

FIG. 3 illustrates several types of roller dies 2, 3 which may be employed with this method. The female dies may be varied as to depth and width of channel and cross sectional configuration of the channel. Thus, the V-shaped channel 4a defined by the female die 2a shown in FIG. 3(A) has substantially the same depth as that shown in FIG. 2, but has a smaller included angle and produces a corresponding included angle of bend, in the sheet 1a. Also, the innermost portion of channel 4a has a curve of greater radius than the corresponding portion of channel 4 shown in FIG. 2. The female die 2b shown in FIG. 3(B) defines a relatively shallow channel 4b having a large included angle and a recessed groove 16 at its innermost portion. The sheet 1b has a large included angle and an upstanding head 17 along the line of bending, which bead is formed by cooperation of an annular rib on the male die 3b with the groove 16 of the female die 2b. The female die 20 shown in FIG. 3(C) has a relatively wide channel with a relatively large included angle and a central upstanding bead 18. The sheet 1c has a relatively large included angle and a recessed bead along the line of bending. As is indicated in FIGS. 3(A)-(C), the configuration of the male die is varied to conform to that of the female die. While beading may be performed within this method (FIGS. 3(B)(C)) this is in the nature of an optional feature and is not in any sense essential to the method of this invention.

The extent to which the male die penetrates into the channel of the female die will effect the angle of bend. Once the angle has been established by selecting a pair of dies of a particular configuration anti fixing their relative positions with respect to each other, the shape of the pattern to be produced may be varied by lateral movement of the sheet as it moves longitudinally through the dies. Simple geometric forms such as curves of various radii, and parabolas, as Well as other symmetrical or asymmetrical shapes and combinations thereof may be readily created by proper lateral movement of the sheet. Straight line bends may be created by fixing the relative lateral position of the sheet-like material as it moves longitudinally through the dies. Thus, the methodof this invention facilitates precise control of the angle of bending as well as the path of bending. For more complex configurations, and for bends with small included angles, repeated passes through the same dies or through various types of dies may be made.

FIGS. 4 through 6 illustrate several of the numerous forms obtainable through this method. The sheet shown in FIG. 4 has been subjected to a single pass through the dies with uniform movement of the sheet in a lateral direction with respect to the dies. The result is a single curved bend or bend line 5. The surface 24 meeting the longitudinally through the dies. Then, by another pass through the dies, the sheet was further shaped by being bent along bend line 10. If desired, the sheet may be inverted for the second pass to impart an angular configuratlOIlIO the formed sheet, rather than the channel configuration shown. The complex pattern shown in FIG. 6 was created by three passes through the dies. It is frequently desirable where complex patterns are to be formed to reverse the direction of curvature at adjacent bends such as bends 20 and 21 of FIG. 6, in order to allow the material to move naturally without distortion. FIGURE 6 also illustrates two curved bend lines 19, 20 which have the same points of origin and termination 22, 23.

It is apparent that numerous types of deformable materials are suitable for this method. Metals, plastics, paper and cardboard as well as laminates thereof, for example, may all be formed by means of this method. This method may be employed with various thicknesses of material and all that is necessary for a change from one thickness to another is that the distance between the male and female dies be altered accordingly.

Where larger, more complex forms are to be made, throat clearance may become an important factor. FIG. 1 shows a means of obtaining clearance for such forming. Upright 27 rests on base 28 and adjustably engages bracket 26 which houses male die 3. The female die 2 is housed in support member 29 which is secured to support arm 30. This results in the space between base 28 and support arm 30 being clear for free movement of the material. For very large sheets, the base 28 may conveniently be placed on the floor, while the support arm 30 is affixed to the ceiling, thus avoiding all throat restriction.

If the sheet is to be moved through the dies by positively driving one or both roller dies, it is by no means critical how this is accomplished. All that is required is that relative longitudinal movement between the roller dies and the sheet be created. Any conventional driving means may be employed. FIG. 2 illustrates an example of a type of driving means which might be used. Driven shaft 11 is journalled in bearing 12 and has bevel gear 13 secured to its lower extremity. As shaft 11 is driven, bevel gear 13 drives bevel gear 14 thereby causing rotation of female die 2 which is rigidly mounted on shaft 15. The male die 3 is rotatably housed in bracket 26. Where clearance is significant, however, it may be desirable to place the drive and transmission means in a position of minimum interference with the roller die area. Alternatively, the metal may be pushed or pulled through idle roller dies or the dies may be translated across a stationary sheet.

With respect to lateral movement, the sheet may be guided and movement controlled by hand, if desired, optionally, a mechanical or electronic guidance system, may be employed. A mechanical cammed arrangement could be used to simply and etfectively provide a means of obtaining increased control and repeatability of a specific pattern.

While for purposes of illustration, reference has been made to specific apparatus capable of being adapted for use in this invention, the illustrations are in no way limiting thereof. For example, it is immaterial what the general orientation the roller dies is so long as the desired relative positioning of the dies with respect to each other is maintained. Thus, they may be mounted for horizontal, vertical or angular feeding of sheet-like materials. Depending upon the orientation selected, the female die may be above, below or beside the male die. Also, it is not essential that the dies be simple individual rollers. For example, two separate rollers whose faces combine to define a generally V-shaped open channel may be employed in lieu of a female die. The male die may remain substantially the same, with forming being accomplished in the same manner.

It is apparent that a great variety of complex shapes may be formed through repeated passes through the same dies or repeated passes through different dies. The angle of bending, configuration of the path of bending and the overall configuration of the form may be varied substantially without the great expense of requiring special single purpose dies and high power presses. Also, the components of a complex form shape may be made separately and subsequently assembled,

Whereas particular embodiments of the invention have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details may be made without departing from the spirit and scope of the invention as set forth in the appended claims.

I claim:

1. A method of forming a three dimensional pattern in a deformable sheet-like material which comprises:

(a) Placing a deformable sheet-like material between and in contact with complementary roller dies;

(b) Forming a bend by applying forces to said material by means of said dies and simultaneously effecting relative longitudinal movement between said material and said roller dies; and

(c) Varying the path of said bend by laterally moving said material, simultaneously with the relative longitudinal movement between said dies and said material.

2. A method of forming a three dimensional pattern in a deformable sheet-like material which comprises:

(a) Placing an edge of a deformable sheet-like material between and in contact with complementary roller dies;

(b) Forming a bend of predetermined angle by applying forces to said material by means of said dies and simultaneously effecting relative longitudinal movement between said material and said roller dies; and

(c) Varying the path of said bend according to a predetermined path by laterally moving said material as it is subjected to said relative longitudinal movement.

3. A method of forming a three dimensional pattern in a metal sheet which comprises:

(a) Placing a metal sheet between a pair of complementary roller dies;

(b) Forming a bend of predetermined angle by applying forces to said sheet by means of said roller dies and simultaneously effecting relative longitudinal movement between said roller dies and said sheet;

(0) Varying the path of said bend according to a predetermined path by laterally moving said sheet as it is subjected to said relative longitudinal movement; and

(d) Forming at least one additional bend by subjecting the sheet to at least one additional pass through said roller dies.

4. The method of claim 3 wherein all bend lines in excess of one are formed on different roller dies.

References Cited UNITED STATES PATENTS 1/1936 Williams 72366 5/1965 Cookson 72-179 

1. A METHOD OF FORMING A THREE DIMENSIONAL PATTERN IN A DEFORMABLE SHEET-LIKE MATERIAL WHICH COMPRISES: (A) PLACING A DEFORMABLE SHEET-LIKE MATERIAL BETWEEN AND IN CONTACT WITH COMPLEMENTARY ROLLER DIES; (B) FORMING A BEND BY APPLYING FORCES TO SAID MATERIAL BY MEANS OF SAID DIES AND SIMULTANEOUSLY EFFECTING RELATIVE LONGITUDINAL MOVEMENT BETWEEN SAID MATERIAL AND SAID ROLLER DIES; AND (C) VARYING THE PATH OF SAID BEND BY LATERALLY MOVING SAID MATERIAL, SIMULTANEOUSLY WITH THE RELATIVE LONGITUDINAL MOVEMENT BETWEEN SAID DIES AND SAID MATERIAL. 